The new system of Rösler reduced the process times significantly, increasing throughput by over 50% compared to the previous setup. Simultaneously, fresh water and compound consumption have decreased thanks to water recirculation, improving cost-efficiency.
Rösler has delivered a highly automated mass finishing solution to the Eingliederungsstätte Baselland (ESB), addressing its need to handle a diverse range of workpieces and materials. The advanced system was designed to modernise processes, simplify operations for employees and enhance environmental sustainability. It includes two rotary vibrators with automatic separation, a conveyor belt linking them to an energy-efficient dryer, and a semi-automatic centrifuge that enables resource-saving recirculation of process water.
“Our systems were outdated and no longer met today's demands in terms of working comfort, ergonomics and sustainability. For example, the parts had to be manually removed from the work containers. In addition, the processes were carried out with fresh water, resulting in a high consumption of water and resources. In addition to the ability to easily process the enormously wide range of components, geometries and materials, the automation of the process and as simple control and handling as possible were key points in the specifications for the investment in new mass finishing systems. It was essential for us to relieve our employees and encourage them to learn new things. Another important requirement was the recirculation of the process water. In addition, the installation situation had to be considered, as the mass finishing processes are carried out in a room in the basement with a door that is only 1.20 m wide,” has stated Sascha Berger, Co-Director at ESB in Liestal.
The Rösler solution includes:
- Two R 220 Euro rotary vibrators: Equipped with tool-free, interchangeable screens for handling different parts.
- RT 150 Euro DH dryer: Featuring energy-saving block heating elements that reduce energy consumption by up to 40%.
- Semi-automatic Z 800 K-HA-TF centrifuge: Designed to efficiently recirculate process water, accommodating the variety of materials processed.
Operators select part-specific programs via the control unit. The system automates processes, including part separation and drying. A pneumatic separating flap ensures media return to the processing bowl, while a natural drying medium is used in the dryer. Safety features prevent part mixing by requiring containers to be removed before new separation cycles begin.
“The key factor in our decision was that Rösler responded to our specifications in great detail and advised us extensively on our specific requirements. For example, the Rösler employee informed us exactly what we needed to consider when treating the process water contaminated with various metals. Tests were carried out at the Customer Experience Center in Kirchleerau for the various components to be machined and used to define the respective machining parameters such as the use of suitable media, compound, processing intensity and time. The data determined in the process were stored as part-specific programs in the system control. During the collaboration and the tests, Rösler provided us with a lot of mass finishing know-how. As a result, we now know what we are doing and what it takes to achieve our mass finishing goals in the best possible way. Basically, people are our top priority and our employees enjoy working with the new system much more. But of course, efficiency is also an aspect that we pay attention to, and we have also achieved a lot here,” has conclude Sascha Berger.